Aerostar AWD V6-183 3.0L (1991)
Removal Of Distributor Gear
8.
Invert distributor and place in axle bearing separator (Rotunda T75L-1165-B, or equivalent) and press off the gear using a press.
CAUTION: To reduce the possibility of distributor drive gear damage, remove the gear as shown in the diagram. If the gear becomes damaged,
the entire distributor assembly must be replaced.
9.
Remove the roll pin from the oil shield (if equipped) and discard, then remove the oil shield from the distributor.
10.
Clean and polish the distributor shaft using emery cloth until the shaft slides easily from the distributor housing, then remove the shaft and thrust
washer (if equipped).
11.
Remove the octane rod retaining screw, then remove the octane rod from the distributor.
12.
Remove the two stator retaining screws, then remove the stator from the distributor.
13.
Inspect the distributor housing bushings for signs of excess heat concentration. Replace the distributor assembly if damaged.
14.
Inspect the distributor housing "O"-ring, replacing if damaged.
15.
Inspect the distributor housing for physical damage, replacing if damaged.
16.
Install the stator assembly in the distributor housing. The alignment tab should fit in the notch on the distributor housing and the fastening eyelets
should be in alignment with the screw holes.
NOTE: Position the wires away from moving parts.
17.
Install the retaining screws and torque them to 15-35 lb. in. (1.7-4.0 N-m).
18.
Install the octane rod, placing the hole in the rod over the alignment pin on the stator assembly. Install the octane rod retaining screw, torquing to
15-35 lb. in. (1.7-4.0 N-m).
19.
Place the thrust washer (if equipped) on the distributor housing. Apply a light coating of motor oil to the distributor shaft below the armature, then
insert the shaft into the distributor housing.
20.
Place the oil shield (if equipped) on the distributor shaft and install a new roll pin.
21.
Place a 1/2" deep socket over the rotor stub, invert the distributor, and place it in a press.
22.
Place the drive gear on the shaft, aligning the marks from step 6.
23.
Place a 5/8" deep socket over the shaft and carefully press the gear onto the shaft until the roll pin holes align, then install a new roll pin.
CAUTION: If the holes do not align, remove the gear as shown in step 9 and reinstall. DO NOT attempt to align the holes with a punch as
damage to the gear and/or shaft may result.
24.
Check the distributor shaft for freedom of movement during a complete rotation of the shaft.
NOTE: If the armature contacts the stator, replace the distributor assembly.
25.
Clean the TFI mating surfaces and apply dielectric silicone compound (Ford D7AZ-19A331-A, or equivalent) to the back of the TFI module.
26.
Install the TFI module and retaining screws, torquing the screws to 15-35 lb. in. (1.7-4.0 N-m).
27.
Install the distributor on the engine, aligning the marks from step 3. Install the distributor hold down clamp and lightly tighten bolt.
28.
Connect the distributor connector, and install the rotor and distributor cap, tightening the screws to 18-23 lb. in. (2.0-2.6 N-m).
29.
Disconnect the SPOUT connector, START the engine, and adjust the ignition timing to 10 degrees BTDC.
30.
Tighten the distributor hold down bolt to 14-21 lb. ft. (19-28 N-m) and connect the SPOUT connector.
